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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #11  
Old 17th October 2020
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randy3934 randy3934 is offline
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remove sprocket cover, may need to remove rear exhaust to accomplish this, mount indicator and measure end play at shaft end "IN OUT" record the measurement for future use, and check for radial play or runout, "UP DOWN SIDE TO SIDE" this will indicate mainshaft roller and race condition.
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  #12  
Old 18th October 2020
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I’m getting pumped to do this, but Im still not sure how to repair the holes. They are so rounded out that I don’t think a hilacoil is made that will fit. I’m tempted to tap a hole for a larger bolt that fits and then tap that bolt for the stock bolt. I need the opinions of a machinist.

Beary



The other bolt in the picture is the stock bolt sitting very loosely in hole to keep debris from falling in the gears.
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  #13  
Old 19th October 2020
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Ferrous Head Ferrous Head is offline
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I've been doing heli-coils and keenserts for years.

But for my race engines I call a mate you has a mobile thread repair business. That's all he does. And he can fix anything that needs a thread.

Google businesses in your local are and you may find some one like that.

Not as expensive as it might seem at first sight. You can buy "Bigserts" that will probably do the job. But you'll need a "kit" to start with that has the required tools.

For just two holes it may be cheaper to pay a professional.

http://www.timesert.com/html/bigsert.html
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  #14  
Old 19th October 2020
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Quote:
Originally Posted by Ferrous Head View Post
I've been doing heli-coils and keenserts for years.

But for my race engines I call a mate you has a mobile thread repair business. That's all he does. And he can fix anything that needs a thread.

Google businesses in your local are and you may find some one like that.

Not as expensive as it might seem at first sight. You can buy "Bigserts" that will probably do the job. But you'll need a "kit" to start with that has the required tools.

For just two holes it may be cheaper to pay a professional.

http://www.timesert.com/html/bigsert.html
Yes, I looked for the timesert size I need and couldn’t find one. I like the idea of a professional. Once and done. That’s why I was thinking machinist, but I will look for a timesert specialist.
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  #15  
Old 19th October 2020
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I use professionals for things that matter. I can weld, I can machine, I can do a lot of things.

But there are people ho do these things over and over every day for a living.

I cannot match their expertise.

I do the things I do and let the experts do the things they do.
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Old 19th October 2020
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I found this discussion on the XLFORUM during my search. Something I had never heard of was the twinsert. That would be a helicoil solution to my problem, but the Keensert appears to be the best solution since the hole is so big.

http://xlforum.net/forums/showthread.php?t=1701138
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Old 26th October 2020
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Quote:
Originally Posted by Beary View Post
I’m getting pumped to do this, but Im still not sure how to repair the holes. They are so rounded out that I don’t think a hilacoil is made that will fit. I’m tempted to tap a hole for a larger bolt that fits and then tap that bolt for the stock bolt. I need the opinions of a machinist.

Beary



The other bolt in the picture is the stock bolt sitting very loosely in hole to keep debris from falling in the gears.
It looks like you don't have much meat around that hole to drill it out for a helicoil. I hope I'm wrong about that. I've seen holes repaired by filling the hole with weld then redrilling/tapping it. That may mean pulling the engine.

If I was planning on pulling the transmission out, I would pull the engine and put it on the workbench. No telling what else you will find.

carl
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  #18  
Old 26th October 2020
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Quote:
Originally Posted by carlgrover View Post
It looks like you don't have much meat around that hole to drill it out for a helicoil. I hope I'm wrong about that. I've seen holes repaired by filling the hole with weld then redrilling/tapping it. That may mean pulling the engine.

If I was planning on pulling the transmission out, I would pull the engine and put it on the workbench. No telling what else you will find.

carl
Someone advised looking for an expert in this area, so I'm doing that. But I did find a keensert with an 1/2 outside diameter and 3/8s inside diameter. I think I need to talk to race car builders. I wonder how I can find those guys.

The more I read about pulling the transmission, the more I'm hesitant. First, as you pointed out, just about all the videos found several other issues (mostly cracks) they had to deal with after pulling the primary cover. Second, just putting the transmission back in the case took several hours with guys that seem to know what they were doing.

What I want to do is build up the bike and then pull the engine while I send everything else to paint. Then I can pull the engine apart and deal with what I find.

I'm not a good welder, so I will have to find someone local. And, there seems to be other little tricks I need to know that aren't in the manuals. I sure would like to find a local Ironhead expert in Oklahoma City. When I ask around, they send me to someone who owns an Ironhead, but is not an a mechanic expert.

Beary
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  #19  
Old 26th October 2020
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Race cars guys are usually found at a racetrack. You don’t need a race car mech, just a skilled mechanic. It’s just bolts and metal.

Guys that take a few hrs to get the trans back in the case may seem like they know what they are doing, they obviously don’t.

I would recommend saving the paint for last as unforeseen engine repairs could be costly. If you budget doesn’t allow, (it may) you will wind up with a freshly painted turd.

Biggest issue with welding that is lack of cleanliness. Without proper prep, it won’t matter who is holding the torch.
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  #20  
Old 27th October 2020
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I'm with Mike.

Before you spend too much money on a bike you need to make a full and proper investigation of the bike. If you discover in months time that the engine had other nmajor problems it might make the whole exercise far too costly.

You are about 160 miles, a 2 1/2 hour drive from some of the best IH experts in the world.

You can take anything you need to be repaired to them. They can build you virtually anything you can imagine.

If nothing else I would spend the time to go and talk to then. These are really nice people. I know you don't have a huge budget for this thing and you want to do it all as cheaply as possible.

In your situation I would seriously consider taking the engine to them for an assessment and maybe even a quote. If you have been inside their premises you'll soon recognise these aren't guys trying to get rich of IH lovers.

At the very least, give them a ring and discuss having them fix your hole problem.

http://www.truettandosborn.com/

If you visit and you say "Please" and "Thank You" they might even show you part of their collection. If that doesn't stimulate you into wanting a nice IH nothing ever will.

They have bikes that you can't even see at Barbers.
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